Valve Body: Service and Repair
Valve Body
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Digital Torque Wrench (V.A.G 1756)
Removing
- Turn off the ignition and disconnect the battery ground cable.
- Remove the transmission fluid filter. Refer to => [ Transmission Fluid Filter ] Service and Repair.
- Make a sketch, identical to the illustration, of all the sensors and solenoid valves and their connectors.
- Mark the solenoid valve and/or sensor and its connector before disconnecting them.
It is absolutely required to draw or take pictures and to make identifying marks so that the connectors to the solenoid valves cannot be interchanged unintentionally when reinstalling the sensors and valve body.
Confusing the connectors could cause damage to the transmission.
- Carefully pry out the connector tabs on the solenoid valves - 1 through 8 - using a small screwdriver and then disconnect the connectors.
The wiring harness or the valve body with the solenoid valves must be replaced if the one of the connectors gets damaged.
- Disconnect the connectors - A and B -.
- Remove the brackets for the connectors - 1 and 2 -.
- Remove the transmission fluid temperature sensor (G93) - 3 - from the valve body.
- Disengage the wiring harnesses from the brackets - arrows -.
- If equipped, bend back the locking plate on the selector lever - arrows -.
- Remove the shift lever - 1 - from the selector shaft.
- When doing this, hold the shift lever - 1 - secure with pliers - 2 - so that it does not turn when removing the multifunction transmission range switch (F125).
- Make sure the slide - 3 - on the valve body in which the shift lever engages is not damaged.
The valve is very sensitive. Even minor damage can lead to a malfunction.
- Always slide the valve into the body, secure it against falling out and never exchange it.
The valve body bolts to the transmission housing have different lengths and must be replaced.
Only the indicated bolts - arrows - may be loosened.
When loosening the other bolts, the function of the valve body can be influenced or the valve body splits up.
- Remove the brackets - 1 and 2 -.
- Loosen the valve body bolts - arrows -, - arrows A - and - arrows B - diagonally and then remove the valve body.
- 3 - Valve body description, for example, A2
- When removing the valve body, pay attention to the piston - 2 -.
- Remove the piston - 2 - with spring.
Installing
- Observe the correct routing of the wires so that they do not get jammed when installing the valve body.
- Route the wiring harness - 5 - into the transmission as illustrated.
The distance - a - must be maintained so that the wiring harness - 5 - does not touch the planetary gear and get damaged when the vehicle is being driven.
- Place the wiring harnesses - 1, 3, 4 and 5 - over the edge of the transmission, as illustrated.
- Attach the wiring harnesses to the transmission with tape.
- Coat the piston - 2 - with transmission and then install it with the spring into the transmission housing, as illustrated.
- Install the valve body and install 2 bolts hand tight.
• Be careful not to pinch the wiring harnesses - 1, 3, 4, and 5 - with the valve body.
Bolt Lengths and Locations on the Valve Body
- Install the remaining bolts and the brackets - 1 and 2 - and tighten the bolts hand tight.
• If the wires are too short to connect to the sensor or to be attached to the valve body, then they were routed incorrectly or they are caught by the valve body. The valve body must be removed again and the wires must be routed correctly.
• Replace the valve body bolts.
- Tighten the valve body bolts working from the inside toward the outside diagonally to specification, refer to => [ Fastener Tightening Specifications ] Fastener Tightening Specifications - Gears, Hydraulic Controls.
- Install the transmission fluid temperature sensor. For the tightening specification, refer to => [ Fastener Tightening Specifications ] Fastener Tightening Specifications - Gears, Hydraulic Controls.
- Connect the 8 pin connector according to the marks made on the solenoid valves. Refer to => [ Wire Routing, Connectors and Valve Body Bracket ] Wire Routing, Connectors and Valve Body Bracket.
Confusing the connectors could cause damage to the transmission.
The wiring harness or the valve body with the solenoid valves must be replaced if the one of the connectors gets damaged.
- Connect the bracket for the connectors, refer to => [ Bracket for Connectors, Securing the Wires ] Wire Routing, Connectors and Valve Body Bracket, tightening specifications, refer to => [ Fastener Tightening Specifications ] Fastener Tightening Specifications - Gears, Hydraulic Controls.
- Connect the connectors - A and B -, see => [ Wire Routing, Connectors and Valve Body Bracket ] Wire Routing, Connectors and Valve Body Bracket.
- Engage the wiring harness - 3 - in the bracket - 7 - - arrow B -.
- Attach the shift lever - 2 - to the selector shaft - 6 -.
When doing this, make sure the pin on the selector lever - 2 - engages into the slide - 1 - - arrow A -. Position the slide if necessary.
- Install the washer - 5 - and nut - 4 - on the selector shaft - 6 -.
The collar on the nut must always face the washer and fit into the washer when the nut is tightened.
The wiring harness must be routed underneath the selector shaft lever.
- Tighten the nut on the shift lever - 1 -. For the correct tightening specification, refer to => [ Fastener Tightening Specifications ] Fastener Tightening Specifications - Gears, Hydraulic Controls.
- When doing this, hold the shift lever - 1 - secure with pliers - 2 - so that it does not turn when installing the multifunction transmission range switch.
- Make sure the slide - 3 - on the valve body in which the shift lever engages is not damaged.
- Bend up the locking plate at the nuts - arrows -, if equipped.
- Install the transmission fluid filter. Refer to => [ Transmission Fluid Filter ] Service and Repair.
- Fill the transmission fluid and check the level. Refer to => [ Transmission Fluid Level, Checking and Filling ] Transmission Fluid Level, Checking and Filling.
- Connect the vehicle diagnostic tester and select "function/component selection".
- Then press "Powertrain".
- After that "6-speed automatic transmission 09G".
- Press "01 - OBD".
- Press "Functions".
- Press "basic setting".